SPRAY FORMING PROCESS

Presented By

Eldho George

Roll No 14

VJCET

Introduction

Spray forming process

Process parameters

Advantages

Applications

Conclusion

References04/17/23 2

Contents:

Introduction :Some of the conventional manufacturing processes are

• Casting,

• Powder metallurgical process ,

• Melt spinning etc………..

The major disadvantages of the conventional manufacturing processes are

• High cost ,

• Inferior properties,

• Long process time.

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Spray forming process- Merits

Attractive alternate.

It is an Unconventional process.

It requires less process time.

Has improved properties.

High flexibility.

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Comparison :

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Spray forming process : It is single step operation

It involves

• Breaking molten metal into droplets .

• Depositing them into substrate.

I.e. the major processes are termed as

• Atomization

• Deposition

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Atomization & Deposition:Atomization is carried out in inert gas atmosphere .

• nitrogen or argon

Molten metal breaks down into small droplets on interaction with high velocity gas jet.

Heat loss occurs by convection and radiation during flight.

Particles impinge on the substrate surface in semi solid state

On Solidification we get the product.

We can alter product shape by relative movement of substrate and atomizer04/17/23 8

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Fig 1 Spray Forming Process Outline

Fig 2. Closed vessel with 150 kg steel melt crucible and tundish04/17/23 10

Process Parameters:

Molten metal flow rate – 5 to 30 kg/minute

Average deposition rate - 0.5 to 5 mm/s

Substrate - atomizer distance - 0.25 to 0.5 m

Spray droplet diameter – 60 to 100 μm

Spray velocity up to 100 m/s

Cooling rate – 10000°C/s

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Advantages :Less no of processes (Single stage operation)

Near net shape

Homogeneous metal matrix composites

Improved mechanical properties (………)

Flexibility ( ………)

Low cost and small lead times (eg )

No recontamination

No macro-segregation of alloying elements04/17/23 12

The major technical challenges of the spray forming process are the following

Quality of master pattern

Formation of oxides

Porosity

Losses due to overspray

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Technical Challenges:

Applications:The major fields of application of the spray forming process are

In rotating parts of aircraft engines

• Ni based super alloys

It is used to produce high speed steels parts

Ultra high strength aluminum – weight reduction

It can produce variety of geometrical shapes like• Billets • Strips, • Tubes ……

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Spray forming is an emerging technology that addresses many classic shortcomings of traditional manufacturing processes.

It leads to manufacture products with

• Homogeneously distributed microstructure.

• Chemical composition.

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Conclusion:

Degarmo, E. Paul; Black, J T.; Kohser, Ronald A. (2003), Materials and Processes in Manufacturing (9th ed.), Wiley.

Dunne. P, Soe.S.P, Byrne G., Venus A., Wheatly A.R., 2003,"Some demands on rapid prototypes used as master patterns in rapid tooling for injection moulding," Journal of Materials Processing Technology, 150, No.3, pp. 201-207.

Grant. P.S., 1995, " Spray Forming,” Journal of Progress in Materials Science, 39, No.4-5, pp.497-545.

http://en.wikipedia.org/wiki/Spray_forming Browsed on 17-7-201104/17/23 16

References:

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THANK YOU

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